METHOD STATEMENT OF STAMPED CONCRETE | STAMPING FLOORING | Floor Stamping | How to do floor stamping ?
METHOD STATEMENT
1. PURPOSE
The purpose
of this Standard Operating Procedure (SOP) is to provide guidance to the installation
team as well as the customer about the process of installing UltraTech Décor or similar
2. APPLICABILITY/SCOPE
This SOP is
applicable to all the project of Stamped concrete
3. INSTALLATION PROCEDURE
Steps to be
followed for Installation of stamped concrete are as follows.
3.1. SURVEY OF THE SITE:
A)
Measurements: Take the proper measurements and make any adjustments prior to
starting the job.
B) Sub
Grade Preparation:
- It should be well drained and should have no free-standing water on the surface.
- It should have required load bearing characteristics.
- The ground beneath the slab needs to be solid.
- Soil should be compacted with machines that eliminate air pockets within the soil.
- In case the concrete is poured on PCC or Existing slabs, it should be cured properly.
- Reinforcements should be used at the Column locations to avoid cracking.
C) Plan out
the Band Pattern (if any), how to lay the stamp pattern, Construction Joints,
control joints properly. There should not be any confusion for these things
after laying the concrete.
4. MATERIAL FOR SITE PREPARATION:
A. There
should be enough forming material to complete the job without interception.
B. Arrange
for steel channel or wooden formwork. Steel channels should not be bent.
5. CHECK TOOLS AND SUPPLIES
A. Some of
the tools which are essential are, Trowels (Magnesium, Wooden and Steel),
Edgers, Pounder, Bull Float (Magnesium and Wooden), Pounder, Fresno, Thermocol,
Tape measure, Stool (Brick Jointer), Brooms, Textured mats, Rolling Tamper,
Sprayers for sealer, acetone, water pump for washing, cutter grinder, brushes
for washing the concrete, cloths for cleaning the stamp mats, Bridge for
stamping, Level Tube (Bottom Patti / Straight Edge)
B. Some of
the materials which are essential are: Colour Hardener, Release agent, Acetone
C. Check
the tools and equipment to ensure that they are clean and in good working
condition.
D. Replace
any tool which is damaged or corroded this time itself.
E. Make
sure that you have proper tools and materials to comply with the local
standards.
F. Check
that you have enough material that you will need to complete the job properly.
6. SAFETY REQUIREMENTs
Following
safety requirements should be taken care on site,
A. Safety
shoes
B. Helmet
C. Jackets
D. Gum
Boots
E. First
Aid Box
7. PREPARE SURROUNDINGS:
A. Use
plastic with masking tape to cover and protect all surrounding areas of the
vicinity where concrete can damage aesthetic of the existing surrounding.
B. Put
Thermocol along the wall and along the columns.
8. CONCRETING PROCESS
A. Minimum
grade of the concrete should be M 30
B. Minimum thickness of slab should be 3”
C. Slump of
the concrete should be max 110 mm
D. Pour the
concrete.
E.
Concreting should be done exactly as per the level given by the architect. This
can be achieved by marking levels prior pouring concrete (DHADA)
F. Level
and finish the concrete by using Level Tube (Bottom Patti / Straight Edge) with
the screed action. We can also use straight edge vibrator ('Mustang' Concrete
Screed) for levelling the concrete.
G. Use
rolling tamper to press the gravels in the concrete. This will help in making
creamy cement slurry on the top of concreting.
H. Finish
the concrete surface by using Magnesium Bull Float. If water cement ratio is
high then we can use wooden bull float for bringing the internal water to come
on top surface.
I. Finish
the edges by using edger.
J. Water
should not be added to the concrete once it arrives at the jobsite.
K. Water
should not be Sprinkled on the concrete once its finished
L. No
single slab should be larger than 15 feet on a side.
M. Fibers
should be used compulsorily, and it may be 600 Gms/cum. But it should be added
on site.
9. COLOUR HARDENER APPLICATION:
A. After
levelling the concrete well next step is to apply colour hardener.
B. Throw
the first coat of colour hardener as per standard procedure. In this step 60 to
70% colour hardener is thrown.
C. Finish
the first coat colour hardener surface by using magnesium float.
D. Throw
the first coat of colour hardener after finishing the first coat.
E. Finish
the second coat colour hardener surface by using steel trowel.
F. By
looking at the finished second coat, if in some places colour hardener does not
look uniform, then at those places throw third coat of colour hardener.
G. It has
to be made sure that there is no undulation on the finished surface.
10. STAMPING PROCESS:
A. Timing
of the stamping is critical for doing a good job. Concrete should be firm
enough to hold the person performing stamping without making a deep impression.
B. Apply
release agent for at least three rows of the stamp mats.
C. Release
agent application should be optimum.
D. Stamping
should be done in a straight line.
E. Make
sure that colour hardener is perfectly levelled.
F. Using
texture mats all corner areas should be stamped first as at the corners
stamping will not be done properly.
G. Place
the stamping mats firmly together.
H. Tamp the
stamp mats with the pounder lightly as we proceed. Some areas we may not use
pounder where concrete is not firm enough.
I. Lift the
edge of the stamp pattern to check to see that imprint is complete.
J. In case
of some stamps (Ashlar slate, English slate), indicates various configurations
such as they are of different colours or marked as A, B, C, D.
K. While
removing stamping mats, grab both the handles one time and lift it straight up
L. As
stamping process proceeds, use small flexible mats and s tool or chisels to
correct any imperfection during stamping.
M. Flexible
mats should not be used anywhere except at the corners. This will help in
reducing the double joints.
N. A bridge
should be made when the width is more. This bridge should be a compulsory tool
in the contractor’s tool kit.
O. Clear
the double lines caused by stamping. We can use margin trowel, chisel or
sometimes reinforcing steel on site to do this
P. Always
clean the tools after finishing the work, this will keep the tools in working
condition for the next project.
11. CURING:
A. After
the concrete finishing is done, the curing process must start.
B. Cover
the slab with plastic sheets, this process keeps water in the concrete so that
the chemical reaction of hydration can continue. Without this water, the
concrete will not reach its design strength.
C. Curing
must be done at least thrice a day for normal climate range.
D. For hot
weather conditions curing must be done at least 4 to 5 times a day that
includes night time too.
12. WASHING:
A. Wash off
excess release after 24 hours by using small capacity pump.
B. Release
agent should be washed after 5 days to achieve desired effect of stamping
colour as specified by the architect. It’s used for double tone effect.
13. CONTROL JOINTS CHECKLIST:
A. For 4
inch thick concrete slab there should be a control maximum of 10 feet in every
direction.
B. Control
joints must be cut after 36 hours of concreting.
C. Mark the
control joint with chalk line or colour available on site.
D. Control
joint depths must be a minimum of 1/3 the thickness of the slab and Control
joint width must be a minimum of 1/16 inch.
E. Joint
thickness near column and intermediate control joints should be minimum 15 mm
and 8 mm respectively.
F. No
vehicle Movement should be allowed at least for 25 days after stamping to avoid
cracks.
14. SEALING:
A. Sealing
should be done at least after 27 days after concreting.
B. There
should not be any moisture present in the concrete slab.
C. For
large areas sealer should be applied by using pump. For smaller areas use
roller or 4 inch brush.
D. Apply
very thin first coat of sealer. This will help in penetrating the sealer in the
concrete slab.
E. Apply
second coat of sealer.
F. If the
surface is still not shiny enough then apply third coat.
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